Suominen nonwovens factory lit up with LED lights
The Suominen Nonwovens factory in Nakkila produces many kinds of nonwoven rolled goods. The product range includes child-care products, women's hygiene, wipes and wound care products. The first phase of the Nakkila LED lighting project was rolled out in November and early December. Energy-saving LED lighting is an integral part of the plant's commitment to sustainable development in the means to save energy. The lighting project will be implemented in three phases with a surface area of 2500 m2 of storage area.
Juha Virtanen, who is responsible for the project, explains the background. “The old fluorescent lamps began to breakdown. The problem was not so much the durability of the bulbs, but of the fluorescent lamp bodies. Especially the newer fluorescent lamps constructed of plastic are easily broken. LED lighting provides an opportunity to reduce energy consumption and maintenance costs.
Previously, the roof had 80 fluorescent lamps that consumed about 83 watts of electricity each. They were replaced by 38 units of the Easy Led PRO 500 industrial lamp with a power consumption of 105 watts per lamp. The power consumption of the calculated total illumination is thus dropped to about 60% of the original.
“In addition, the replacement costs of fluorescents and the additional working hours used are left out of this cost saving calculation. We have to use shatterproof fluorescent lamps, which are considerably more expensive than normal fluorescent tubes,” continues Smith.
Further savings the company has yet to realize come from dividing the illuminated area into three regions, each of which is controlled by its own motion sensors. Months of follow-up are required to analyze the usage of these storage areas because the lights will now only be on for 20-45% of the time compared to continuous usage on other parts of the site and with the older lights. These intelligent and adaptive uses of lighting control solutions improve energy efficiency. The use of sensors with LED lighting is ideal because the lamps reach their full lighting capacity immediately without any negative long term effects of bulb longevity.
Total luminosity increasing while number of lamps decreasing
While the number of lamps installed to the ceilings is decreasing there is more total light. The PRO-Series lighting controls the opening angle of the light output and better allows light to be directed to where it is needed.
The workers in the storage area have been largely content with the new lighting. Kimmo Sallinen, who works in the warehouse, is satisfied with the LED installation. “The light is quite sufficient. Despite the brightness of lights, they do not blind,” says Sallinen. Glare is reduced due to the large opening angle of the lamps. ”Glare is not a problem even on high lifts,” says Sallinen. Workers also noticed the quality of lighting that is "much better than before".
LED lighting is also possible to implement were previously it was not possible or sensible. In the past, the need for adaptive lighting control solutions at Suominen’s nonwovens factory were applied to the security lighting of the corridor where lamps were connected an uninterrupted power supply (battery) in the back.
Suominen’s lighting modernization is proceeding to the next stage in the near future when a second, slightly higher warehouse is outfitted with LED technology. In addition, the energy conservation project will provide concrete data that is currently being compiled with measurements from the installations.